A site that machines, tests and overhauls drivetrain and hydraulic assemblies for military land vehicles. Each machine, rig and bench with a read path goes onto one record per asset, on the site's own servers.
Every machine and rig keeps its own records on its own PC, with its own clock. A failed test run is pieced together from three places. Audit evidence for a serial number is assembled by hand from binders and spreadsheets.
A read-only edge reads each asset over an interface it already has, or one the survey confirms. Pragmatos puts those assets on one record with one clock, on servers inside the site. The data stays on the site.
Pragmatos does not run a machine, a rig or a test cell, and it releases no part. It touches no weapon or mission system. It reads, records and shows.
Four results for a site of this size, each with its inputs on card 7. Overhaul turnaround is shown, not counted.
A site like this has three halls. The machining hall makes housings, shafts and gears. The test hall runs every finished gearbox, hydraulic unit and power pack before release. The overhaul shop strips, repairs and re-tests assemblies that come back from service. Most of the equipment was bought in different decades, from different makers.
| Zone | Asset | IDs | Maker | In since | Read path | Where its data lives today |
|---|---|---|---|---|---|---|
| Machining | 5-axis machining centres ×6 | M-01…06 | A · B | 2009 · 2019 | Existing interface | Each machine's own panel |
| Turning centres ×4 | M-07…10 | C | 2004 · 2016 | Existing interface | Each machine's own panel | |
| Coordinate measuring machines ×2 | CMM-01, 02 | D | 2014 | Survey | Report files on the measuring PC | |
| Heat-treatment furnace | HT-01 | E | 1998 | Survey | A chart recorder and a paper batch card | |
| Test hall | Gearbox test rigs ×3 | TR-01…03 | F | 1994 · 2012 · 2023 | Existing interface Survey for TR-01 | A rig PC each, three file formats |
| Hydraulic test benches ×2 | HB-01, 02 | G | 2008 | Existing interface | The bench PC and a printed run sheet | |
| Power-pack test cell | TC-01 | H | 2017 | Existing interface | The cell's own control PC | |
| Overhaul | Networked torque tools ×8 | TQ-01…08 | I | 2020 | Survey | The tool controller's own log |
| Overhaul bays ×4 | OB-1…4 | – | – | Survey | Paper job cards and a whiteboard | |
| Site | Calibration register, gauges and torque tools | – | – | – | Entered once per instrument | A spreadsheet of due dates |
| Compressors and hall power meters | – | J | mixed | Survey | The site meter, read monthly |
Makers are lettered, not named. Survey means the interface survey confirms a read path before the scope is fixed. An asset without one stays out of scope until it has one.
A gearbox comes back from service with a fault report. Its last acceptance run sits on the 2012 rig PC, its measuring report on the CMM PC, its last overhaul torque values in a tool controller's log, and the calibration status of every gauge in a spreadsheet. Before any work starts, someone collects all of it by serial number.
Five tags are industry-wide pressures, sourced below. The sixth comes from the site's own induction. The site already has the data for each. It is never on one record.
A read-only edge on the site network reads each asset over the path the survey confirmed. The edge holds about 72 hours if the link to the server drops. Pragmatos Live gives every value a name, a timestamp and an asset ID, on servers inside the site.
The edge has no write path. Pragmatos does not start a run, set a load or change a machine program. It releases no part and signs no record. Engineers and inspectors decide; Pragmatos gives them one record to decide from. It connects to production, test and maintenance equipment only.
An assembly moves through an overhaul shop bay by bay, and nothing leaves a bay until it is signed. The rollout follows the same order. Each bay door shows its weeks, and each step is signed before the next asset is added.
| Bay | Weeks | Step | What happens | Signed by | Card |
|---|---|---|---|---|---|
| 1 | 0 – 1 | Induct | The site's IT and security team sets the rules for the servers inside the site, and the edge's place on the network. | IT and security lead | Perf Insp |
| 2 | 1 – 3 | Survey | Lists what each asset records today and confirms a read path for each one. Assets without a path are named out of scope. | Manufacturing and test engineers | Perf Insp |
| 3 | 4 – 8 | Connect | Machining hall first, then the test hall. The asset IDs and tag names are agreed. Availability runs per asset. | Production manager; test-hall lead | Perf Insp |
| 4 | 9 – 12 | Rules | Test runs are tied to serial numbers. Stop-cause rules and calibration-due rules go live once a named engineer approves them. | Quality engineer | Perf Insp |
| 5 | 13 – 14 | Release | The first evidence pack per serial goes to the quality team, and roles and the change history are checked against the site's own rules. | Quality manager | Perf Insp |
Each row counts the same thing twice, block for block: hollow blocks for today, filled blocks with one record. Fewer blocks is better. Every input is on card 7 and can be replaced with the site's own figure.
Engineer-days a year spent assembling traceability evidence by serial number: measuring reports, test runs, torque values and calibration status.
About 36 runs a year fail and need a cause. Today each takes 12 hours to line up the rig file, the machining history and the overhaul record; with one record, 3.
Hours lost to unplanned stops. The hours that come back are stops with a cause on the record, so the repeat is fixed rather than met again.
Runs repeated because a channel, a timestamp or a serial was missing from the record, not because the unit failed.
Total, a year, for a site of this size (card 7, Total row). The four do not overlap. R2 counts failures that still happen; R4 counts only runs repeated for a gap in the record. Overhaul turnaround and readiness are shown on the record, not counted here.
€144,225| Row | Input or step | Value | Kind |
|---|---|---|---|
| C-01 | Engineer-day, loaded cost | €850 | ASSUMED |
| R1 · Audit and acceptance evidence | |||
| C-02 | Engineer-days a year assembling evidence by serial number, today | 48 | ASSUMED |
| C-03 | The same, with one record | 12 | ASSUMED |
| R1 | (C-02 − C-03) × C-01 | €30,600 | DERIVED |
| R2 · Failed test runs pieced together | |||
| C-04 | Rigs, benches and test cells in the test hall | 6 | ASSUMED |
| C-05 | Test runs a year, all of them | 360 | ASSUMED |
| C-06 | Share of runs that fail and need a cause | 10% | ASSUMED |
| C-07 | Failed runs a year = C-05 × C-06 | 36 | DERIVED |
| C-08 | Hours to piece one together, today | 12 | ASSUMED |
| C-09 | The same, with one record | 3 | ASSUMED |
| C-10 | Hours a year = (C-08 − C-09) × C-07 | 324 | DERIVED |
| R2 | C-10 ÷ 8 × C-01 | €34,425 | DERIVED |
| R3 · Machining-hall hours found | |||
| C-11 | Machining centres and turning centres | 10 | ASSUMED |
| C-12 | Planned hours a machine a year, two shifts | 4,000 | ASSUMED |
| C-13 | Share of planned hours lost to unplanned stops | 8% | ASSUMED |
| C-14 | Hours lost a year = C-11 × C-12 × C-13 | 3,200 | DERIVED |
| C-15 | Share that comes back once every stop has a cause | 15% | ASSUMED |
| C-16 | Hours back a year = C-14 × C-15 | 480 | DERIVED |
| C-17 | Contribution per machine-hour, with a full order book | €110 | ASSUMED |
| R3 | C-16 × C-17 | €52,800 | DERIVED |
| R4 · Test runs repeated for an incomplete record | |||
| C-18 | Runs repeated a year for a gap in the record, today | 15 | ASSUMED |
| C-19 | The same, with one record | 4 | ASSUMED |
| C-20 | Cost of one repeated run: rig hours, technician, energy | €2,400 | ASSUMED |
| R4 | (C-18 − C-19) × C-20 | €26,400 | DERIVED |
| Total | R1 + R2 + R3 + R4 | €144,225 | DERIVED |
ASSUMED a stated input for a site of this size; replace it with the site’s own figure. DERIVED arithmetic on the rows above.
Not counted: overhaul turnaround, the share of assemblies ready for issue, and calibration overruns. They are shown on the record and left out of the total, because their value depends on contracts this sheet cannot see.